Brewing system with electrical controller and method

ABSTRACT

A twin brewer system ( 30 ) with a pair of brewers ( 30 A,  30 B) each with a controller ( 158 ) for controlling the application of electrical power to a hot water heater, disables the application of electrical power to the heater ( 154 ) of one brewer ( 30 A,  30 B) in response to actuation of a start brew switch of the one brewer ( 30 A,  30 B) while electrical power is being applied to the heater ( 154 ) of the other brewer ( 30 A,  30 B). The controllers also respond to a hot water quantity sensor ( 164, 168 ) and a responsive delay circuit for disabling dispensing of hot water in response to actuation of the brew start switch ( 50 ) until a sufficient quantity of hot water is in a hot water dispenser tank ( 152 ) needed for the brew cycle. Indication lamps indicate when the brew cycle is being delayed and when brewing is not being performed. Actuation of a single emergency stop switch ( 138 ) stops hot water dispensing of both brewers ( 30 A,  30 B).

CROSS REFERENCE TO RELATED APPLICATION

This application is a division of 08/932,498, filed Sep. 18, 1997, nowU.S. Pat. No. 5,953,981 which claims the benefit of U.S. ProvisionalApplication, No. 60/026,275, filed Sep. 18, 1996, and entitled “BrewerSystems, Apparatus and Methods of Operations and Use”, the contents ofwhich are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to electrically powered brewingapparatus and more particularly to high volume brewing systems withbrewing apparatus operated by electrical controllers.

2. Description of the Related Art Including Information Disclosed Under37 C.F.R. 1.97-1.99

For large gatherings of people, such as conventions, large banquets,etc., there is a need for huge volume coffee production systems. Theseknown systems produce six gallons of coffee at a time in six gallonremovable urns and can also store up to two hundred forty gallons ofcoffee in one or more sixty gallon holding tanks to which the freshlybrewed coffee is selectively automatically transferred. The removableurns are kept in hot water filled liners in which the water is kept hotby means of an electrical, gas or other heating element. Likewise, thestorage, or holding tanks, have liners in which circulated the heatedwater to keep stored coffee hot.

In coffee brewers which have the capacity to alternatively fill twodispensers, so called “twin brewers”, or “double brewers”, only onecontroller of the brewing cycle with a single power supply and only onewater tank and heater are provided. Limitation on the coffee brewingrate of the system is not imposed by the water supply but by theelectrical power service required. The hot water dispenser valve whichmust open to pass hot water from a hot water holding tank through thebrew basket containing the coffee or other brew material to start thebrew cycle will not open until the water temperature in the hot waterholding tank has reached the proper temperature and the speed at whichthe water in the hot water holding tank can be reheated after one brewcycle to commence another brew cycle is determined in the case of anelectrical heater by the amount of electrical power available to theheating element. Because there is only one hot water tank for both ofthe twin brewers in known systems, enough hot water to fill at leastboth urns must be heated before either side of the brewer can start anew brew cycle, or the brew cycle of neither side of the brewer can beoperated until the other side has completed its brew cycle and the waterhas again been reheated.

In known high volume coffee brewing systems, as the water in hot watertank is dispensed through a brew basket, new water is added to the hotwater tank to maintain a constant pressure head and uniform flow. Thisis done so that the volume of hot water dispensed can be controlled bycontrolling the time that the hot water dispensing valve is kept openduring the brew cycle. Accordingly, the twin brewer must draw power toheat the water being added during the brew cycle. Because the removableurns in known brewing systems must be kept warm by a hot water liner,they also require additional electrical power for this purpose inaddition to the power needed to heat the hot water holding tank.

Because of these electrical power requirements, the brewing rate ofknown high volume systems is limited by the level of electrical powerservice available at the brewing site. Because of this approach used inknown twin brewer brewing systems, the brewing rate is limited to 0.75gallons/minute (or 45/hour).

Turning to another problem with known twin brewing systems, should thesingle controller or its single power supply fail, both sides of thetwin brewers and thus the entire brewing system becomes completelydysfunctional; neither “side” of twin brewer will work.

Yet another problem with known brewing systems with holding tanks towhich freshly brewed coffee is transferred is that the transfer functionis automatically performed even in the event of a full tank and theemergency stop switch for one brewer in a twin brewer has no effect onstopping transfer from a second brewer.

SUMMARY OF THE INVENTION

The principal object of the invention is to provide a high volumebrewing system, apparatus and methods which overcome the abovelimitation and disadvantages of known high volume brewing systems,apparatus and methods noted above.

The object of the invention is achieved by providing a twin brewerbrewing system having a pair of brewers, one and another, each includinga hot water tank, a hot water electrical heater for heating the water, adispenser mechanism for controlled dispensement of the hot water in thehot water tank through a brew basket, a controller for controlling theapplication of electrical power to the heater to heat the hot water andan electrical power supply for the controller and means associated witheach of the controllers of each one of the pair of brewers for disablingthe application of electrical power to the heater of the one brewer inresponse to actuation of a start brew switch of the one brewer whileelectrical power is being applied to the heater of the other brewer.

Also, the object of the invention is obtained by providing in a brewingsystem having a hot water dispenser tank for containment of apreselected amount of water needed for a complete brew cycle, means forselectively dispensing the hot water in the hot water dispenser tankinto a brew basket during a brew cycle and a manually actuatable brewcycle start switch for initiating the brew cycle, the improvement beinga brew cycle controller having means for sensing when the hot waterdispenser contains the preselected quantity of water needed for a brewcycle, means for storing the occurrence of manual actuation of the brewcycle start switch and means responsive to both the storing means andthe sensing means for controlling the selective dispensing means todelay dispensing of water into the brew basket in response to anactuation of the brew cycle initiation switch until the sensing meanssenses that the preselected quantity of water needed for a brew cycle iscontained in the hot water dispenser tank if the brew cycle start switchis actuated to start a brew cycle before the hot water dispenser tankcontains the preselected amount of water.

Obtainment of the object is achieved by providing in a brewing systemhaving a brew cycle start switch to start a brew cycle and a brew cyclestatus light associated with the start switch, with a brew cycle statuslight controller having means for causing the light to operate in afirst mode of operation if the brew cycle start switch has not beenactivated to start a brew cycle, means for causing the brew cycle statuslight to operate in a second mode different from said first mode inresponse to actuation of the brew cycle start switch before the brewingsystem is enabled to properly perform a brew cycle and means for causingthe brew cycle status light to operate in a third mode different fromboth said first and second modes during performance of a brew cycle.

Moreover, the object of the invention is obtained in a brewing systemhaving a brewer, a holding tank and means for transferring beverage fromthe brewer to the holding tank with a transfer controller having a firstmanually actuatable bistable switch controlling automatic transfer ofthe beverage to the holding tank upon completion of a brew cycle and asecond manually actuatable monostable switch for manually controllingselective transfer of the beverage to the holding tank only while thesecond monostable switch is manually held in the on state, saidmonostable switch automatically returning to an off state to stop thetransfer of the beverage when not manually held in the on state.

Still, the object is obtained by provision of a twin brewer brewingsystem comprising a pair of brewers each including its own brew basket,hot water dispenser tank, brew cycle start switch, means for controllingthe dispensing of water from the hot water dispenser tank into the brewbasket in response to actuation of its own brew cycle start switch, asingle emergency stop switch for both of the pair of brewers and meansresponsive to actuation of the emergency stop switch for causing thedispensing controlling means of both of the pair of brewers to terminatetransfer of hot water.

Also, the object of the invention is achieved by providing a twin brewersystem comprising a pair of brewers each including a transfer switch andmeans transferring beverage from each brewer to a holding tank inresponse to actuation of the transfer switch, an emergency stop switchand means responsive to actuation of the emergency stop switch forpreventing the transferring means of both of the pair of brewers fromtransferring beverage to the holding tank.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing objects and advantageous features of the invention will beexplained in greater detail and others will be made apparent from thedetailed description of the preferred embodiment of the presentinvention which is given with reference to the several figures of thedrawing, in which:

FIG. 1A is a front view of a double brewer system comprised of a doublebrewer, a beverage storage tank and a transportable double brewerdispenser aligned beneath the brewer for receipt of brewed beverage;

FIG. 1B is a side view of the double brewer FIG. 1A together with thetransportable double brewer dispenser shown in FIG. 1A;

FIG. 1C is an enlarged front view of the control switch panels of FIG.1A;

FIG. 1D is an enlarged sectional side view of the brewer system of FIG.1A showing the mating guide members on the beverage storage tank and thedispenser cart for both double dispensers.

FIG. 2A is a bottom view of the double brewer of FIG. 1A with a singletransportable brewer dispenser mounted to a cart and aligned beneatheach of the two brewers;

FIG. 2B is a bottom view of the double brewer similar to that of FIG. 2Abut with both carts removed;

FIG. 3A is a bottom view of a mobile single brewer system of the presentinvention and having a portable single brewer dispenser on a cartlocated in an operative position to receive beverage;

FIG. 3B is a bottom view of the mobile single brewer system of FIG. 3Abut with the cart located in an inoperative position removed from thebrewer;

FIG. 4A is a front elevation view of another embodiment similar to thedouble brewer brewing system of FIG. 1A but equipped with a pair singleinlet dispensers and a mechanism to facilitate manual removal of thedispensers from the brewer for transfer to a service cart or the like;

FIG. 4B is a side elevation view of the brewer system of FIG. 4A;

FIG. 4C is another side elevation view of the brewer system of FIG. 4Awith the removable dispenser moved to an inoperative position tofacilitate removal from the brewer;

FIG. 4D is a side elevation view of one of the dispensers of the brewingsystem of FIGS. 4A-4B and an associated cart;

FIG. 4E is a single brewer embodiment of the brewing system in which thebrewer is adapted for mounting on a special stand;

FIG. 4F is a front elevation view of mobile stand that may be used withthe brewer of FIG. 4E in lieu of the special stationary stand of FIG.4E;

FIG. 5A is a front elevation view of a brewing system of the presentinvention with transfer mobile and stationary twin brewers connected forpassage of brewed beverage to one or more substantially identicalholding tanks;

FIG. 5B is an enlarged front elevation view of the control panels of thetransfer brewers of FIG. 5A;

FIG. 6A is a sectional side elevation of a twin brewer of the presentinvention in which each brewer has its own hot water tank and heatingelement and level sensors;

FIG. 6B is a plan view of the twin controllers and heating elements witha communication cable attached to enable coordinated operation of theheating elements;

FIG. 7A is partially schematic wiring diagram and partially functionalblock diagram of the controller including an EPROM in which a controllerprogram is stored and associated indicator status lights and switches,all generally shown as FIG. 3;

FIG. 7B is a plan view of a cart and in which the controller of FIG. 7Ais mounted including three connector sockets for removable receipt ofsolid state timers for setting the time period for the by-pass cycle,the brew cycle and the flush cycle;

FIG. 7C is a side view of the preferred embodiment of the solid statetimers that plug into the circuit of FIG. 7A;

FIG. 7D is a front elevation view of the solid state timer of FIG. 7C;

FIG. 8A is an enlarged sectional side view of the enlarged storage tankof FIG. 5A showing the spray nozzle head assembly used to flush down thesides of the storage tank to clean and sanitize it;

FIG. 8B is an enlarged cross sectional view of a portion of the holdingtank of FIG. 8A;

FIG. 8C is an enlarged cross sectional view of a portion of the mobiledual inlet dispenser and mobile single inlet dispenser;

FIG. 9A is a plan view of the brew basket used in the brewers of thepresent invention and showing the double walled construction forcreation of a bypass trough;

FIG. 9B is a sectional side view of the brew basket assembly of FIG. 9A;

FIG. 10A is a side view of the dispenser with a portion shown in sectionto illustrate a movably mounted brew basket support member with the brewbasket in operative position sealed engagement with the bypass/dispenserassembly to receive beverage directly from the brewer;

FIG. 10B is a sectional side view similar to that of FIG. 10A but inwhich the brew basket has been located adjacent to its operative alignedposition before it is carried into sealed engagement with theby-pass/dispenser assembly or it is removed; and

FIG. 10C is a side view similar to that of FIGS. 10A and 10B but inwhich the brew basket has been entirely removed from alignment with thehot water dispenser for removal of the filter holder and storing thebrew basket drainage hose.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIGS. 1A, 1B and 1C, a preferred embodiment of a mobiletwin brewer system 30 is seen which includes a pair of substantiallyidentical brewers 30A and 30B symmetrically mounted in side-by-sidesymmetrical relationship within a single rectilinear housing, or frame,32. The rectilinear housing includes a base 34 supported above a floor36 by five substantially identical legs 38, and the base 34 supports anelongate, upright aft housing section 40 with an upper aft housingportion 40A and a lower aft housing portion 40B.

The upper aft housing portion 40A, in turn, supports a forward housingsection 42 in cantilever relationship suspended at a preselectedrelatively elevated position above the floor 36, as best seen in FIG.1B. The cantilevered forward housing section has an upper cantileveredhousing portion 42A and a lower cantilevered housing portion 42B.Mounted to the forward face of the upper cantilevered housing portionare two control panels 44A and 44B of manually actuable control switchesand associated status indicator lights respectively associated with thepair of brewers 30A and 30B as best seen in FIG. 1C. The switches andlights of control panels 44A and 44B are connected with a pair ofassociated electronic controllers (not shown) protectively containedwithin the upper cantilevered housing portion 42A.

Referring to control panel section 44A shown in FIG. 1C, each of thecontrol panels 44A and 44B includes a power on/off switch 46 to controlthe application of AC power to the associated brewer, a “ready to brew”indicator light 48 to indicate when the associated brewer 30A or 30B isready to start a brew, a brewer start switch 50, a “stop brew” switch 52to manually stop the brew cycle of the associated brewer and amonostable “flush” switch 54 for controlling a flushing operation of theassociation brew system, all as described in more detail below.

Referring again to FIG. 1A, the lower cantilevered housing portion 42Bsupports in cantilevered suspended relationship with the floor 36, abrew/by-pass hot water distributor assembly 56 and a brew basketassembly 58 for each of the brewers 30A and 30B. During a brewing cycle,hot water from a separate hot water dispenser tank for each of thebrewers 30A and 30B (not shown) mounted within the aft housing section40 is allowed to flow downwardly by passing or flowing through groundcoffee contained within the brew basket assembly 58 and out through abeverage outlet 60 at the bottom of the brew basket assembly 58.

In keeping with an important aspect of the invention, the cantilevermounting of the forward housing section 42 positions the beverage outlet60 at precisely the correct height above the floor and the correctforward distance from the front 40C of the aft housing section 40 toensure correct depth alignment of a single inlet mobile dispenserassembly 62 with single one of the twin brewers, such as the right sidebrewer 30A shown in FIGS. 1A and 1B, or with a substantially larger dualinlet mobile dispenser assembly 64 shown in FIG. 1B. When the back 62Aof the single inlet mobile dispenser assembly 62 and the back 64A, FIG.3A. abuts against the front 40C of the aft housing section 40, themobile dispenser assemblies 62 and 64 are correctly aligned depth-wisefor receipt of brewed coffee directly into the mobile dispensers 62 and64, respectively. Depth alignment is assisted and lateral alignment isensured by means of leg guides 66A and 66B, on the left, and leg guides68A and 68B, on the right, shown in FIG. 1A and described in greaterdetail below with respect to FIGS. 2A, 2B, 3A and 3B.

Still referring to FIGS. 1A and 1B, the single inlet mobile dispenser 62includes a cart assembly 64 with a support platform 64A, supported, inturn, by a frame 64B, supported, in turn, by a base 64C. The base 64C issupported by a matched pair of forward, outer wheels 64D and a matchedpair of aft, pivotally mounted inner steering wheels 64E, all assembletogether in a generally trapezoidal relationship to support the singleinlet mobile dispenser for rolling motion along the floor surface 36.Wheels are provided with brakes. Facilitating rolling the single inletmobile dispenser 62 along the floor are a pair of handles 64F at thefront of the card assembly 64. An adjustably mounted sink, or drip tray,68 having substantial depth is mounted to the frame 64G by means ofposts (not shown) which fit into a pair of horizontally aligned key holeslots 64H (only the unused pair shown).

The single inlet dispenser 66 has a thermally insulated containerdefined by side walls 66A with a closed bottom 66B resting upon theplatform 64A and an open top with an insulated lid 66C to which ismounted a centrally located inlet funnel 66D for direct receipt offreshly brewed beverage from the beverage outlet 60 when in verticalalignment, as shown in FIG. 1B. After the dispenser 66 is filled withthe desired amount of coffee as shown by a glass gage 66F, the dispenserassembly 62 is rolled out from beneath brewer 30B using handle 64F toany desired remote location for dispensing of coffee into individualcups or urns by means of a faucet 66E. After the dispenser 66 is filled,the inlet funnel 66D is closed with a removable vent cap 420 (not shown)to prevent spilling during transport and reducing heat loss. Theinsulated cover 66C is releasably locked in place by means of clampsscrewed down tight by means of threaded knobs 66G secured down onthreaded posts. The clamps are released and the cover 66C removed bymeans of a pair of handles 66H for access to the interior of thedispenser for cleaning. These handles 66H alternatively are used to liftthe entire single inlet dispenser from off the platform 64A.

The twin brewer system 30 alternatively is used with a single inletdispenser assembly 64, as shown in FIG. 1A, simultaneously with a pairof mobile single inlet dispenser assemblies 62 or is used in cooperationwith a series of dispenser assemblies 62 which are necessarily filled byeach brewer.

In addition, as seen in FIG. 1D, the twin brewer assembly 30 is alsoadapted to cooperate with a mobile dual inlet dispenser assembly 70similar to the mobile single inlet dispenser assembly 62 of FIGS. 1A and1B. The dual inlet dispenser assembly 72 is permanently mounted on acart 74 rollable across a floor 36 into a mating position with the twinbrewer assembly 30. In the mating position, both of a pair of perimitalinlet nozzles 72A and 72B are in vertical alignment with the beverageoutlets 60 of both the left side brewer 30A and the right side brewer30B to simultaneously directly brew freshly brewed coffee from bothbrewers into the one dispenser assembly 72. Like the mobile single inletdispenser assembly 62, the dual inlet dispenser assembly 70 has a set offour wheels 72 supporting a frame, or housing, 74 which, in turn,supports the dual inlet dispenser 72. The dual inlet dispenser has aninsulated body 76, an insulated lid 78 to which the inlet funnels 72Aand 72B are mounted. The lid 78 is releasably clamped to close an opentop of the body 76 by means of clamps tightened down with knobs 80. Themobile dual dispenser assembly 70 also has a sink 82 adjustably mountedto the fan 74 by means of key hole slots 84. The dual dispenser assembly72 also has a handle 86, a level gage 88, a pair of aligned faucets 90and 92 on opposite sides and a relatively lower centrally located faucet94. The dual dispenser holds approximately 24 gallons of coffee and,thus, is not adapted for removal from support by the frame 74.

Depth alignment of the dual inlet funnels 72A with the beverage outlets60 is achieved when the back of the dual inlet dispenser 70 is pressedagainst the front 40C of the housing section 40, same as with the singleinlet dispenser assembly 62 as shown in FIG. 2A. Depth alignment isassisted. Lateral alignment is achieved by means of interior guidemember 66A and 66A′ of the shown brewer assembly 32 cooperating withguide means 68B and 68B′ for the dispenser assembly, as well asdescribed in greater detail with reference to FIGS. 2A, 2B, 3A and 3B.

Referring first to FIGS., 2A and 2B, each of the mobile single inletdispensers 64 carriers adjacent the floor 36 a pair of elongate,symmetrically arranged male guide members 68B and 68B′ which are guidedby engagement with guide legs 66A and 66A′ of the twin brewer assembly30. The guide members have formed beveled sections 96 pointed inwardlytoward each other to cause the guides upon engagement with the forwardedges of guide members 66A and 66A′ cam toward the center of the space98 between guide members 66A and 66A′. Also, they have shoulders 98extending perpendicularly outward from each other which engage theforward surface 100 of the guide members 66A and 66A′ to block furtherinsertion to assist in achieving proper depth alignment.

As seen in FIGS. 3A and 3B, the same guide members 66A′ which cooperateson opposite sides with the interior guide member 68B′ of the mobilesingle inlet dispenser assemblies carts, functioning as female guidemembers, also function as a male guide member which cooperates with agenerally rectilinear female guide member 102. Guide member 102 has apair of parallel side walls 104 with beveled ends 106 for causingengagement with the end 100 of center or interior guide member 66A tofacilitate receipt of the guide member 66A between parallel side walls104. A stop member 106 extending between the side walls 104 engages theforward surface 100 of guide member 66A to block further forwardmovement to assist in correct depth alignment. In addition, when guidemembers 66A are fully inserted between guide member 102, rounded corners108 abut against the forward wall of aft housing 40 to also assist incorrect depth alignment.

Thus, in using the brewer system of FIGS. 1A-3B, an operator need notever manually lift or move a dispenser into and out of cooperativerelationship with the brewing system and, moreover, can directly brewinto a large capacity dual inlet dispenser that would be too heavy forone person to lift. In addition, with the mobile dual inlet dispenser72, both brewers can be used simultaneously to brew beverage directlyinto the dispenser. The same guide members on the twin brewer 30 areused to correctly align both mobile single inlet dispenser assemblies 62and mobile double inlet dispenser 70. In using the twin brewer, anoperator rolls the mobile dispenser into correct alignment with thebeverage outlet 60 of one or both of the brewers 30A and 30B using thecooperating guide members, brews the coffee into the dispenser and whenthe desired amount has been received, removes (rolls) the dispenser fromengagement with the brewer 30 to a service location, thereby making roomfor another mobile dispenser to be moved into engagement with thebrewer.

Another embodiment of the twin brewer 30′ is shown in FIGS. 4A and 4Bwhich is substantially identical with the twin brewer 30 of FIGS. 1A-3B,except that instead of being equipped with the capacity of directlybrewing beverage into a mobile single or double dispenser assembly, itis equipped with a pair of single inlet dispenser and a mechanism tofacilitate manual removal of the single inlet dispenser from the brewerfor manual transfer to a service cart or the like. In addition, thelower aft housing section 40B has been removed, and instead, the aftupper housing 40A′ is supported on a base 34′ and four legs 104 above acounter top 106.

Instead of being supported on a platform 64A mounted on wheels, thesingle inlet dispenser 66 is mounted on a movably mounted dispensershelf 108 which is slideably mounted on an elongate pair of paralleltracks 110 as best seen in FIG. 4C. Preferably, these tracks 110 haveU-shaped channels in which wheels 111 are carried for ease of movementby a shelf mounting member 112 which is fixedly attached to the shelf106. As seen in FIG. 4C, a handle 114 at the front of shelf 108 isaccessible to manually pull the shelf 108 and the single dispensercarried by the shelf 108 from an operative position aligned beneath thebeverage outlet for receipt of the brew as shown in FIG. 4B, to aloading/unloading position as shown in FIG. 4C in which a person isenabled to stand alongside the dispenser and other side gain betteraccess to the handles 66H without having to lean over the top of thedispenser or slide the dispenser relative to the shelf 108. The shelf108 is moved to the loading position to place an empty dispenser on theshelf 108 and is then slid or rolled backward to the operative brewerposition. After the dispenser has been filled with the selected amountof brew, the shelf 108 and the loaded dispenser are then slid forwardagain to the forward load position. The dispenser is then manuallylifted off the shelf 108 while in the load/unload position and thenmoved to another location directly or first moved onto a mobile servicecart.

As seen in FIG. 4D, the service cart is preferably the same as theservice cart assembly 64 of the mobile dispenser 62. In addition, thedispenser preferably has a boss 116 with a threaded hole within which athreaded bolt 118 carried by the service cart is matingly received toprevent the dispenser from falling off the cart. The threaded bolt ismounted for relative sliding movement along the slot 120 to facilitatealignment with the threaded hole of the bore 116.

As shown in FIGS. 4E, the brewer 30A or 30B of the twin brewer 30′ arealternatively mounted alone in their own individual housing. Such singlebrewers are adapted for mounting on special stands 120 which support theshelf 108 at substantially the same height of the service cart assemblyof FIG. 4D.

As soon in FIG. 5A, other versions of the mobile twin brewers 30 shownin FIG. 1D and the twin brewer 30′ of FIGS. 4A and 4B. Transfer mobiletwin brewer assemblies 120 and transfer stationary twin brewerassemblies 122, respectively, which are capable of transferring freshbrew from the associated brewer to one or more substantially identicalholding tanks 124A and 124B. As shown in FIG. 5B, the control panels126A and 126B of these transfer brewers have control switches additionalto the control panels 44A and 44B associated with the transfercapability. In addition to the power switch 46, the ready indicator 48,the brew start switch 50, the stop switch 52 and the flush switch 54′,each of the control panels have two transfer switches: an automatictransfer on/off bistable switch 128 and a monostable manual transfercontrol switch 130 that must be manually held in an on state in order toeffect transfer.

Each of the transfer brewers 120 and 122 have a pump (seen in FIG. 7A),one or more transfer lines, or conduits, 132 and associated valve andconnections to enable actuation of the pump and transfer of the freshlybrewed beverage from the brewer to the first holding tank 124A withwhich it is connected. A line 134 with a manual control valve 136selectively interconnects the storage tanks for transfer between thetank 124A and 124B before the first tank is filled. Otherwise, the firstholding tank 124 must first be filled before there is overflow to fillthe next holding tank 124B. When the automatic transfer switch 128 ison, the pump operates automatically to transfer the coffee to theholding tanks as explained below. On the other hand, transfer can beselectively controlled by manual actuation and holding of the manualhold transfer switch 130.

The flush switch 54′ in combination with the transfer switch is used toflush the pump (not shown), the transfer lines 132 and the holding tanks124A and 124B.

Referring again to FIG. 5B, the third additional switch is an emergencystop switch, or power assist break/reset, 138. When this bistable switch138 is pushed in, all brew and transfer functions cease and power to thebrewer is disconnected. When the switch 138 is pulled out to reset thebrewer and re-establish power, the controller required the brew cycle tobe restarted and the original brew cycle in process when the emergencystop switch was actuated will not be allowed to continue.

Referring again to FIG. 5A, each of the holding tanks holdsapproximately 60 gallons of brew, has an upper faucet 140 at an upperlevel which is preferably used when the tank is filled to reduce headpressure and a lower faucet 142 at a relatively lower level and when thelevel of the brew is below the level of the higher faucet 140. Theholding tanks also each have an insulated body, a removable insulatedcover 144 with handles 146, a head gage 148 and are supported on stands150 substantial identical for mounting the stationary twin brewer 122.The first tank 124A is directly connected to each of the brewers 120 and122 by their own line 132. Although only two holding tanks 124A and 124Bare shown, each brew unit has capacity for connection with at least onetank and each tank has capacity for inlet connection with multiplebrewers and outlet connection with an inlet of another tank.Accordingly, any number of tanks can be connected in series.

Referring to FIGS. 6A and 6B, an important feature of the twin brewersystem is that each of the two brewers is self-contained and is capableof operating individually of the other brewer should the other brewcease to function properly. At the same time, the twin brewers operatein a coordinated fashion to achieve speed of production equal or betterthan that of known nonindependent systems which require a high level ofelectrical service, such as 220 VAC, with a lower level of service morecommonly accessible, such as standard 110 VAC electrical service.Referring to FIG. 6A, this is made possible, as will be explained indetail below because each brewer, brewers 30A and 30B, is provided withits own separate hot water tank 152, with its own individual electricalheating element 154, with its own power supply, with its own watersupply control to and from tank 156 and its own controller 158. There isa single water connection and electrical power connection for the twinbrewer but the connections immediately branch off to the two separatebrewers.

Because of the separate water tanks, dispensing a fixed amount ofbrewing levels 160 and 162 defined by the ends of level sensor 164 andthe level of brew 166, from the hottest part of the tank adjacent thetop and connection of all electrical power to the heating elements 154of only one hot water tank 152 at a time, a relatively rapid heating ofthe hot water in tank 152 through use of standard 120 VAC power insteadof 220 VAC is achieved.

Still referring to FIG. 6A, each brewer is also seen to contain a secondlevel sensor 168 for detecting when the water is beneath the normallowest level during operation such as when the tank is first beingfilled. Each of the brewers also contain a by-pass valve 170 whichprovides hot water from the tank 152 to a by-pass location above theannular trough 172 of a brew water distributor 174 for a selected timeperiod at the beginning of each brew cycle or during a flush operationunder control of controller 158. A brew water dispenser valve 176selectively passes hot water to a brew water dispenser location suitablylocated above a central bowl 178 of the distributor 174. The bowl 178 isisolated from the annular, or doughnut shaped, distributor by-passtrough 172. Water from the trough 172 drops through an annular gap 180between the perimeter of a brew basket 182 and a filter 184 holding thecoffee 186 in a central location beneath the bowl 178 to by pass thefiler 184. Both the by-pass water from valve 170 and the brew water fromvalve 176 and bowl 178 passing through the coffee 186 exit through thebrew outlet 60 and into the inlet funnel 66D. The duration of the timeperiods for the by-pass cycle and brew cycle are determined by plug inelectrical times 188 of the controller 158. During a flush cycle, bothvalves 170 and 176 and opened simultaneously.

As illustrated in the top sectional view of the brewer of FIG. 6A, eachof the controllers 158 share connection with the emergency stop andpower reset switch 138 and have a communication line 182, they otherside are entirely self contained with all their own components,including their own DC power supplies 184, control switch panels 126(connections not shown) and circuit cards 186.

Referring to FIGS. 7A and 7B, the machine is ready to start a brew cyclewhen the water is at the correct temperature and the tank is full. Ifthe water requires heating, L1 400 is switched to T′STAT terminal. Whenthe control recognizes this, a relay contact 402 will close and switchL1 from the T′STAT terminal to the HEAT CONT 404 terminal which willenergize the heater contactor. When the water is at the propertemperature, L1 400 is removed from the T′STATE input which willde-energize the heater contactor. The control will now open the relaycontact 404 between the T-STAT terminal and the HEAT CONT terminal. whenthe external level control senses that water is required, L1 is switchedto the LLC FILL terminal 406. L1 is then routed through a N.C. contactof TDR1 and out the FILL SOL terminal, energizing the fill solenoid 408.When the external level control does not require water, L1 will not bepresent on the LLC FILL terminal. If the heat is off and the fill is offthe control will now turn on the READY lamp output. A brew cycle may nowbe started. The READY lamp will turn off again whenever the fillsolenoid or heat is requested.

To start the brew cycle, press the BREW button 50. The control willlatch L1 to TDR1-1 common relay terminal 410. The control will thenrecognize this via internal circuitry connected to the TDR1-4 N.C.contact. The control will now energize K2 switching L1 to TDR1-2 andTDR2-2 power input energizing the TDR1 and TDR2 interval timers. Thecontrol will begin to flash the BREW lamp output 50′. TDR1 will nowenergize the brew solenoid and TDR@ will energize the bypass solenoid414. The second set of contacts on TDR1 (TDR1-5 and TDR1-8) will opendisable the LLC fill output from energizing the fill solenoid 408 duringa brew cycle. When TDR times out, the fill solenoid 408 will de-energizeand L1 will again be switched to TDR1-4 contact. The control will againrecognize this and turn off the latching relay removing L1 from TDR1 andTDR2. The control will stop flashing the BREW lamp output 50′. The brewcycle is now complete. TDR2 would not be set longer than TDR1 since TDR1sends the signal to the control that the cycle is over. At this time theconnection will be re-established between the LLC fill output and theFILL SOL terminal allowing the vessel to be filled again. If a brewcycle is started before the READY light 48′ is on, the control will turnon the power latch and turn on the BREW lamp 50′ solid but will notenable the interval timers until the water is up to temperature and thetank if full.

Upon the completion of the brew cycle, if the AUTO TRANSFER switch 128is closed, the control will begin the transfer cycle. At this time L1will be switched to the TDR3-2 power input terminal starting the TDR3interval cycle. L1 400 will be switched to the transfer pump terminalenergizing the transfer pump 303. Internal circuitry in the control willrecognize that the transfer pump 303 is energized and not allow a newbrew cycle to take place. During the transfer cycle, the control willflash the AUTO lamp 128′. Upon completion of the transfer cycle, thetransfer pump will de-energize, the AUTO lamp will stop flashing and thecontrol will now allow a new brew cycle to begin when the water is atthe proper temperature.

AUTO TRANSFER

When the Auto Transfer switch 128 is closed, the control automaticallyperforms the transfer function following a brew cycle. When the AutoTransfer 128 switch is not closed, the transfer must be performedmanually. The control can also recognize the manual transfer and willnot allow brew cycle to take place when the transfer pump is energized.The AUTO lamp 128′ output will be on solid if the transfer switch isclosed and the transfer function is not taking place. The AUTO lamp 128′will flash any time the transfer pump 303 is energized.

LINKED OPERATION

The brew cycle in the linked mode of operation is as previouslydescribed with the following exceptions.

The controls are connected with a communication cable 416 as seen inFIG. 6B. In this mode of operation only one unit at a time will beallowed to turn on the Heater contactor 404. The controls continuallymonitor the integrity of the cable. Should the cable 416 open a line,both controls will cease operation and flash three lamp outputs tosignal a communication link error. Power must be removed and thecondition corrected. Also in this mode of operation the communicationscircuitry can determine if power has been removed from the other controlallowing the unit which is powered-up to have the heat whenever it isrequired as in the stand-alone mode of operation. When the second unitis powered-up again, the linked mode operation will resume as previouslydescribed.

Referring now to FIGS. 8A and 8B, another advantageous feature of theholding tank 124, identical to holding tanks 124A and 124B of FIG. 5A,is the provision of a flushing mechanism which includes a spray nozzle300 centrally mounted at the end of a centrally located upstandingconduit 302 which, in turn, is connectable to a pump 303, FIG. 7A, ofthe brewer through a conduit 304, manually controlled valve 306, conduit308 and connector 310 through a detachable flexible hose 312. First,move the transfer hose 418 as seen in FIG. 4A from the parking positionon the side of the brew head you want to transfer. Insert it into thetop of the sight glass 66F on the dispenser after removing the vent cap420. Second, select the Transfer, Automatic, ON push button above thebrew head you wish to transfer to holding tank activating pump 303 topump hot water form the urn through conduit 132 and into the holdingtank 124.

Hot water is pumped through the hose 312 when it is desired to flush theinterior of the holding tank 124 with hot water from the brewer to rinseclean and sanitize the interior surfaces 314 of the walls 315 and theinterior surface 316 of the removable lid 144. As indicated by thedotted lines 318 representing the hot water flow during a flush cycle,the cleansing hot water is caused to impinge on the interior surface 316of the lid 144 at acute angles to cascade across and down these surfaceswith a high velocity spray to obtain a dynamic cleansing action superiorto merely soaking the surfaces as done in the past.

Referring to FIG. 8B, which is an enlarged cross sectional view of aportion 320 of the holding tank 124 adjacent the juncture of the lid 144and the side walls 315, another advantage of the brewing system of thepresent invention is that the side walls 315 and the lid 144 have adouble wall construction with insulating material sandwiched between thedouble walls. The lid 144 has a top wall 322 and a bottom wall 336 withsolid insulation 338. The double wall 315 has an outer wall, or jacket,336 and an inner wall, or liner, 340 between which is sandwichedinsulation layer 340 which is the same solid insulation material as inthe lid 144, preferably TRYMER. In addition, thermal insulation isprovided between the interior metal surface of the lid and the sidewalls of the tank. The top, or exterior, wall 322 of the lid 144 isisolated from the interior wall 336 and secured thereto around theperimeter by means of a strip 342 of an insulating cement-like or otherinsulating material, preferably TRYMER. This insulating strip is inaddition to isolating the wall 322 from wall 336 also isolates the wall336 from the end 340′ of interior side wall 340. Another thermallyisolating strip 342 of insulating material, preferably TRYMER, securestogether and thermally isolates the outer wall 338 and the liner wall,or liner, 340. No interior metal, which is highly thermally conductive,is in contact with any outer metal and the internal surface 336′ has ahighly reflective surface to reflect heat downward for optimum thermalinsulation of the coffee.

Each of the dispensers, both single inlet and double inlet, have thesame thermal insulation and isolation construction as shown in FIG. 8B.Due in part to this thermal insulation of all dispenser, etc. the needto provide additional heat to the dispensers or tank is eliminated andless electrical power construction is required for operation.

The mobile dual inlet dispenser and mobile single inlet dispensersimilarly have double walled insulated construction. As seen in FIG. 8C,the cover 78 and side walls 76 have a double walled construction withinsulation 338 and thermal lid isolation lid members 342A and 342B andside wall thermal isolation member 342C.

Referring now to FIGS. 9A and 9B, showing the spray disk 345 in FIG. 9Ahaving a central bowl 178 which receives hot water from the brew valve176 and separates the brew water into large number of separate showersthrough a matrix of holes 346 to covet the entire bed of coffee. Thebypass valve 170 passes hot water into the bypass trough where hot wateris diverted around the coffee bed and passes through a matrix ofdrainage holes 344 into the brew basket and mixes at the bottom of thebrew basket with the brewed coffee.

Referring to FIG. 9B specifically, spray disk 345 has an annular wall348 that separates the trough 172 from the bowl 178 such that the levels350 and 352 of accumulated water are not necessarily the same and theby-pass period has ended and the brew water begun to pass through thecoffee 186. The brew basket has a base 354 and is snugly fitted at itstop 356 against the bottom 358 of the by-pass/brew water dispenser 174to block the upward escape of heat and steam from within the brew basket180.

This sealing engagement is achieved despite the brew basket beingmounted for sliding movement into and out of engagement with thedistributor by means of a movably mounted brew basket mounting assembly356 shown in FIGS. 10A, 10B and 10C. The brew basket 180 is removablymounted within a drawer-like frame 358 within which the brew basket isnestled and secured against downward or lateral movement relative to theframe 358. The frame 358, in turn, is mounted for gliding translationalmovement by means of opposed sets of slideably engaged track 360 and 362cooperating with rollers 364 which operate like file drawer slides.Pulling on the handle 366, an operator can slide the brew basketmounting assembly from the operative position shown in FIG. 10A to theposition shown in FIG. 10B at which the brew basket 180 can be easilylifted vertically out of the frame 358 using handles 368. A new brewbasket is then inserted and the drawer-like frame 356 is slid “closed”.The frame is mounted at a slight angle relative to the bottom 358 of thedistributor such that the leading edge of the top 356 of the brew basketis beneath the bottom 358, and the top 356 of the brew basket does notengage the bottom 358 until the frame has been almost fully inserted asshown in FIG. 10A. At that position a cam surface, schematicallyillustrated by cam number 370, lying in the path of the leading bottomedge of the frame causes the leading edge to rise to the level the top356 and press it snugly against the bottom 358.

General reference should be made to all the drawing figures for thefollowing discussion of the preferred use and detailed discussion of theportions of the twin brewer 30 of FIG. 1A and the single brewing system121 of FIG. 4E. The twin brewer 30, as noted, is comprised of two singlebrewers 121 mounted within a single housing and with a line ofcommunication or communications cord. Different steps are followeddepending upon which brewer is being operated and whether it is mountedon a stand for use with the mobile dispensers or is only mounted on acounter.

FIG. 5B:

Push the power switch 46 to the ON position on each brew head to beused.

Each brew head has a computer 158, as seen in FIG. 6B, that will notallow a brew to start until the ready light 48 for that head turns on.However, a brew cycle can be selected at any time and the computer 158will begin the cycle as soon as it is ready. The ready light 48 is onwhen the hot water tank connected to the brew head below the light isfull of water, the water is up to the proper temperature, and thetransfer, if selected, has finished. The transfer function does notdelay the fill or heating functions. How long it takes for the readylight 48 to come on the first time each day and between brews depends onthe electrical specifications issued when the brewer was ordered.Depending on the electrical power available, twin brewers 30 with thetransfer option may be configured to allow only one brew head to heat upat a time. This delay in the heating process is important only during acold start when the first brew head must come up to temperature beforethe second head can start to heat. After a cold start heat delay, thenormal heat delay drops to only a few minutes. Depending on theelectrical power and water temperature available, the normal heat delaymay not be noticed by the operator.

Each dispenser 62 must be preheated before you brew coffee into them tomake sure that the finished coffee will be as hot as possible. Anysource of hot water is sufficient, even the brew head itself by usingthe Flush button 54. Fill the container to approximately half full onthe sight glass with hot water and wait at least 10 minutes beforedraining and brewing into the dispenser.

Before making any coffee that will be transferred to a holding tank,make one full brew in each head, without coffee in the brew basket, andthe Automatic transfer button 128 in the ON position. This water onlybrew will push hot water through all the coffee transfer hoses andcomponents to the holding tank 144. The hot water both rinses andpreheats these components. Be sure to turn on the rinse jet 300 in theholding tank 144 for several minutes for the same rinsing and preheatingaction used on the brewer. Finally, drain the holding tank beforetransferring coffee into it.

Open the drawer 356 holding the brew basket 180 very carefully and makesure there is not any hot coffee or grounds trapped inside. Remove thebrew basket by first sliding the drawer 180 holding the basket 180 outof the brew head to its stop, as seen in FIG. 10C. Turn the brew basketby one handle 368 until you can reach both handles comfortably. Now grabboth handles 368 and raise the basket up until it can clear the drawer356 and remove it. If necessary, empty any old coffee grounds and cleanthe brew basket.

Place one paper filter in the brew basket. Into this paper filter placeyour ground coffee. Smooth the coffee in the filter until it is auniform depth.

Pull the brew basket drawer out to its stop and place the brew basketinto it. Rotate the brew basket and align one handle, left or right,with either front corner of the drawer. This rotation keeps the brewbasket handles from hitting the brewer body when the drawer is closed.Close the drawer. The drawer will be flush with the face of the brewerwhen in the fully closed/brew position. Twin brewer with transfer optionmounted on Counter—proceed with steps 7 & 8, skip 9 & 10. Twin brewerwith transfer option mounted on Stand (for serving carts only)—proceedto steps 9 & 10. Twin brewer with transfer option mounted on Split Stand(for serving carts & dispenser drawer)—proceed with steps 7 through 10.

Open drawers holding dispensers as seen in FIG. 4C very carefully tomake sure there is not any hot coffee inside the dispenser. The transferhose will have to be parked on the side of the brew head as seen in FIG.4B before the dispenser drawer can be opened. Due to the weight of adispenser with coffee inside, the dispenser must be drained beforeremoval from the drawer by one person. Two people are required, one oneach handle 66H, to carefully remove a full dispenser. The empty or fulldispenser can be removed from the drawer for cleaning or transportationon the 6 gallon serving cart. Remove the dispenser by fully extendingthe drawer and lifting the dispenser 1 inch to clear the retaining lipon top of the drawer. If necessary, empty and or clean the dispenserbefore starting a fresh brew.

Extend the dispenser drawer to the full open position. Place a clean andempty dispenser inside the retaining lips on the drawer with the faucetfacing out. Slide the drawer back into position in the brew head. Theface of the dispenser will be flush with the face of the brew basketdrawer when in the proper position.

When using the 6 gallon dispenser with cart, the 18 gallon mobil servingtank, and the 24 gallon mobil serving tank (18 gal. and 24 gal. mobileserving tanks are not usable with the split stand), always insure thatthe coffee liners are clean and empty.

CAUTION: ALWAYS INSPECT THE COFFEE SIGHT GAUGE AND THE COFFEE LINER TOMAKE SURE IT WILL HOLD THE NUMBER OF 6 GALLON BREWS YOU INTEND TO MAKE.The carts are parked under the brew head/heads with the operatorsteering handles and faucets facing out. Make sure that the front faceof the coffee compartment is flush with the face of the brew basketdrawer. When using the 6, 18 and 24 gallon carts, make sure that thebrew basket opening is above the coffee dispenser cover opening/s.

CAUTION: ALWAYS SET BOTH PARKING BRAKES ON THE CART. The brakes shouldbe set whenever the cart is not traveling and not under “hands oncontrol” of the operator. NEVER park the cart under the brewer with out,A) insuring it is fully in the brew position, and B) setting the parkingbrakes. The brakes are set by pressing your foot on the paddle 37 asseen in FIG. 1B just above and to the rear of each steerable wheel 64E.When the brakes are set, a green button extends above this paddle. Thisgreen button is the brake release button. The brakes are released fortraveling by pressing the green button with you foot. For a moredetailed description on using the cart, refer to the appropriate cartsoperation manual.

Main control board and computer. The function of the main control boardis to manage the timed functions, interface with the operators switches,remember the operator switch commands until they can carried out, systemerror detection, and the heater electrical power management in anintegrated fashion. Each brew head has its own mail control board. Themain control board carries the computer and the timers. Watertemperature is controlled by the thermostat exclusively but the decisionof when and which water tank in a twin brewer is allowed to heat is madeby the main control board. Water level in the hot water tank/s is sensedby the liquid level control boards dedicated to each tank. The maincontrol board monitors the LLC to insure the brewer is ready for thenext brew cycle and inhibits the fill cycle during the brew cycle.

Fill system/liquid level control board. The function of the fill systemis to control the incoming water so as to maintain sufficient amount ofwater in the brewer to complete a coffee brew cycle. Each brew head hasa separate hot water tank and each tank has its own liquid level controlboard (LLC). The LLC controls the hot water tank water inlet valve andprovides status reports to the main control board. The LLC uses 2 watersensing probes, one upper and one lower. The water inlet valve is openeduntil both probes are touching water. The lower probe is used to sensethe presence of enough water in the tank to allow the heaters to come onwithout danger of burning the heaters out. When water is not felt by thelower probe, the LLC signals the main control board to prevent theheaters from coming on. The upper probe senses when the hot water tankis full to the brew level. When the upper probe senses water, it turnsoff the water inlet valve and signals the main control board to allowthe next brew cycle. During the brew cycle, the water inlet valve isinhibited by the main control board from refilling the hot water tank.When water is taken from the hot water tank during the activation of theflush button, the LLC automatically refills the tank to the brew levelagain.

Heating system. The function of the heating system is to bring thetemperature of the incoming water up to the proper degree to brewcoffee. Each brew head has a separate hot water tank and each tank hasits own thermostat. The thermostat is preset at the factory to 205degrees F. The thermostat operates independently of other systems in thebrewer but can be inhibited from heating in 3 ways. 1) if there is notenough water in the hot water tank to reach the lower water level probe,as in the first start up after installation or loss of water supply,heat is inhibited by the LLC via the main control board. 2) during thebrew cycle, heat is inhibited by the main control board. 3)if the maincontrol boards on two brew heads are connected by a communicationscable, the main control board will allow only one set of heaters to drawfrom the incoming power source at a time. Which ever tank calls for heatfirst will lock out the other tank until it is done. The second tankwill begin heating as soon as the first tank finishes. The thermostatwill attempt to heat whenever the water falls below 204 degrees.

Dispense systems. The function of the dispense system is to deliver brewwater to the brew basket to accomplish the brewing of coffee. Thedispense system for each brew head is comprised of a brew valve and brewtimer, a bypass valve and bypass timer, the spray disc and bypass donut,and the hot water tank. The main control board interfaces the operatorbrew start and brew stop buttons to these valves. The flush button opensthese two valves directly and does not go through the main controlboard. The maximum water volume of 6 gallon is permanently set by thefactory by way of the position of the brew and bypass valve at the 6gallon level on the side of the hot water tank. The brew timer is set tohold the brew valve open until the 6 gallons has drained from the tank.On models with the transfer feature, the brew time is extended beyondwhat is required to finish a 6 gallon drain to delay the transfer pumpcycle. This delay time (brew time extension) is set to allow the coffeetransfer pump to begin at such a time as to allow the pump to finishshortly after dripping from the brew basket stops. These steps in thetiming cycles allow AT brewers to be adjusted for maximum brew volumeper hour. The main control board on all brewers inhibits the LLC fromrefilling the hot water tank until the brew and bypass valves close.This interaction of valve position and tank filling guarantees that thebrew volume is both repeatable and predictable. The repeatable andpredictable nature of the dispense system allows the timer to be set toallow any amount of brew temperature water up to 6 gallons to drain aswell. The brew valve empties onto the spray disc. The spray discseparates the brew water into a large number of separate streams toshower the entire surface of the coffee bed in the brew basket with hotwater. The bypass timer is set to hold the bypass valve open to achievethe desired percentage of bypass. The bypass valve empties the bypasswater into the bypass donut where it is diverted around the coffee bedin the brew basket and into the coffee container along with the brewedcoffee. From 0 to 40% of the brew water volume can be diverted in thismanor. The main control board can delay the start of the brew cycleuntil the brewer is ready. I.E. proper temperature, full water tank, andthe transfer if applicable is completed.

Switches and what they do

POWER (ON / OFF), extended push button, latching switch. The poweron/off switch light is on with the switch in the on position. The switchturns the power on/off only to the brew head below the switch.

READY (TO BREW) light only. The ready light is on when the hot watertank connected to the brew head below the light is full of water, andwhen the water is up to the proper temperature. Each brew head on thebrewer has a ready light. How long it takes for the ready light to comeon the first time each day and between brews depends on the electricalspecifications issued when the brewer was ordered. Depending on theelectrical power available, twin brewer 30 and single brewer with thecommunications cord, may be configured to allow only one brew head toheat up at a time. This delay in the heating process is important onlyduring a cold start when the first brew head must come up to temperaturebefore the second head can start to heat. After a cold start heat delay,the normal heat delay drops to only a few minutes. Depending on theelectrical power and water temperature available, the normal heat delaymay not be noticed by the operator.

BREW (START), momentary push button. To speed the brew cycle, theBrew/Start can be selected before the brew head is ready. If theBrew/Start is selected before the brew head is ready, the Brew/Startlight will turn on and remain on while waiting for the brew head tobecome ready. Two conditions must be met before the brew head willbecome ready and start the brew cycle. The tank must be full of water,and the water must be up to temperature. If the Brew/Start switch hasalready been pushed, the brew head will automatically start the brewcycle when these two conditions have been satisfied. The Brew/Startlight will flash during the actual brew cycle.

STOP (BREW), momentary push button, no light. Stops and cancels the brewcycle on the brew head below the switch. The brew cycle can not berestarted from the point that it was stopped. If the brew cycle iscanceled, you must start over.

FLUSH (HOLD), momentary push button, no light. Press and hold the flushbutton to open both the brew and bypass valves. Hot, brew temperature,water will flow into and through the brew basket and bypass donut intothe dispenser for as long as this switch is pressed. This function isused primarily to rinse the brew head at the end of the operating cycle,shift, or day. Flush can also be used to preheat the brew head anddispensers before their first use of the day.

CAUTION: You can overfill the Dispenser if you hold this button in longenough.

10 AMP CIRCUIT BREAKER (PUSH TO RESET), protection for all of theleft/right side brew head electrical components and function switches isprovided by this breaker. Each brew head, left or right on twin brewers,has a separate breaker. Brew Timer. (front timer) Adjustable in onesecond increments

The time required on this adjustment will need to be the minimum timerequired to clear the hot water tank of the complete 6 gallons neededfor brewing. Brewers with the transfer option will require additionaltime (variable to each coffee, grind, weight, and spray disc selected)needed for drip out. The object of this additional time is to delay thetransfer start time long enough to insure the transfer finish time isonly slightly longer than the time needed for the brew basket to finishrapid dripping. The proper amount of time added to the minimum brew timeinsures that the transfer will be complete and that the dispenser willbe empty for the next brew. If the additional time is longer thanneeded, the gallons per hour of coffee production will be reducedunnecessarily. Always inspect the dispenser to verify that a transferwas successful before starting another brew cycle. Remember that thetransfer time is also adjustable and will effect this adjustmentslightly.

Bypass Timer. (middle timer) Adjustable in one second increments

Refer to the bypass chart below for settings needed to obtain any % ofbypass required. Remember, both the bypass timer and the brew timer mustbe adjusted when changing the bypass percentage. Essentially this meansthat as you increase bypass % the brew time will need to be reduced andvisa versa. Please refer to the chart because these changes are notequal I.E. 25 seconds up on the bypass timer does not mean 25 secondsdown on the brew timer.

Timer settings - With/out TRANSFER Extend minimum brew time to suittransfer % of Bypass Timer Minimum Brew Time Bypass Seconds = Vol.Seconds = Vol.  5%  .3 5.7 Gal. Gal. 10%  .6 5.4 Gal. Gal. 15%  .9 5.1Gal. Gal. 20% 1.2 4.8 Gal. Gal. 25% 1.5 4.5 Gal. Gal. 30% 1.8 4.2 Gal.Gal. 35% 2.1 3.9 Gal. Gal. 40% 2.4 3.6 Gal. Gal.

1. Transfer Timer. (back timer) Not used on 71A & 72A

1. Brew water to coffee contact time.

Coffee contact time can be controlled by the size and total number ofholes placed in the spray disc in the spray assembly.

Select your coffee grind below-then the contact Coffee time at left Con-Coarse Med. Grind Fine Grind Custom Grind tact Grind hole hole hole holeTime-Min. # Size Pattern # Size Pattern # Size Pattern # Size Pattern4.0 Min. 4.5 Min. 5.0 Min. 5.5 Min. 6.0 Min. 6.5 Min.

1. Leveling

It is very important that the brewers, counters and stand be leveledwith an accurate spirit level. Each brewer, counter, and stands haveadjustable feet. Leveling must be done prior to bolting the feet down.If the foot mounting holes for bolting are not aligned with the holesprovided when the brewer is level, a slightly back lean is preferred toany forward leaning of the brewer.

The twin brewer system 120 and 122 with the ability to transfer coffeeto the holding tank 124A and 124, shown in FIG. 5A are operated in amanner in part the same and in part differently from the operation ofthe nontransfer single brewers 122 and twin brewer 30. The transferbrewer 120 (serving cart) and 122 are both referred to as a twin brewerand are handled somewhat differently as described below.

The steps to successfully prepare a freshly brewed beverage with thetransfer option as seen in FIG. 5A can be appreciated as follows. Startby pushing the power switch 46 to the ON position on each brew head tobe used.

Each brew head has a computer 158, as seen in FIG. 6B, that will notallow a brew to start until the ready light 48 for that head turns on.However, a brew cycle can be selected at any time and the computer 158will begin the cycle as soon as it is ready. The ready light 48 is onwhen the hot water tank connected to the brew head below the light isfull of water, the water is up to the proper temperature, and thetransfer, if selected, has finished. The transfer function does notdelay the fill or heating functions. How long it takes for the readylight 48 to come on the first time each day and between brews depends onthe electrical specifications issued when the brewer was ordered.Depending on the electrical power available, twin brewers 30 with thetransfer option may be configured to allow only one brew head to heat upat a time. This delay in the heating process is important only during acold start when the first brew head must come up to temperature beforethe second head can start to heat. After a cold start heat delay, thenormal heat delay drops to only a few minutes. Depending on theelectrical power and water temperature available, the normal heat delaymay not be noticed by the operator.

Each dispenser 62 must be preheated before you brew coffee into them tomake sure that the finished coffee will be as hot as possible. Anysource of hot water is sufficient, even the brew head itself by usingthe Flush button 54. Fill the container to approximately half full onthe sight glass with hot water and wait at least 10 minutes beforedraining and brewing into the dispenser.

Before making any coffee that will be transferred to a holding tank,make one full brew in each head, without coffee in the brew basket, andthe Automatic transfer button 128 in the ON position. This water onlybrew will push hot water through all the coffee transfer hoses andcomponents to the holding tank 144. The hot water both rinses andpreheats these components. Be sure to turn on the rinse jet 300 in theholding tank 144 for several minutes for the same rinsing and preheatingaction used on the brewer. Finally, drain the holding tank beforetransferring coffee into it.

Open the drawer 356 holding the brew basket 180 very carefully and makesure there is not any hot coffee or grounds trapped inside. Remove thebrew basket by first sliding the drawer 180 holding the basket 180 outof the brew head to its stop, as seen in FIG. 10C. Turn the brew basketby one handle 368 until you can reach both handles comfortably. Now grabboth handles 368 and raise the basket up until it can clear the drawer356 and remove it. If necessary, empty any old coffee grounds and cleanthe brew basket.

Place one paper filter in the brew basket. Into this paper filter placeyour ground coffee. Smooth the coffee in the filter until it is auniform depth.

Pull the brew basket drawer out to its stop and place the brew basketinto it. Rotate the brew basket and align one handle, left or right,with either front corner of the drawer. This rotation keeps the brewbasket handles from hitting the brewer body when the drawer is closed.Close the drawer. The drawer will be flush with the face of the brewerwhen in the fully closed brew position. Twin brewer with transfer optionmounted on Counter—proceed with steps 7 & 8, skip 9 & 10. Twin brewerwith transfer option mounted on Stand (for serving carts only)—proceedto steps 9 & 10. Twin brewer with transfer option mounted on Split Stand(for serving carts & dispenser drawer)—proceed with steps 7 through 10.

Open drawers holding dispensers as seen in FIG. 4C very carefully tomake sure there is not any hot coffee inside the dispenser. The transferhose will have to be parked on the side of the brew head as seen in FIG.4B before the dispenser drawer can be opened. Due to the weight of adispenser with coffee inside, the dispenser must be drained beforeremoval from the drawer by one person. Two people are required, one oneach handle 66H, to carefully remove a full dispenser. The empty or fulldispenser can be removed from the drawer for cleaning or transportationon the 6 gallon serving cart. Remove the dispenser by fully extendingthe drawer and lifting the dispenser 1 inch to clear the retaining lipon top of the drawer. If necessary, empty and or clean the dispenserbefore starting a fresh brew.

Extend the dispenser drawer to the full open position. Place a clean andempty dispenser inside the retaining lips on the drawer with the faucetfacing out. Slide the drawer back into position in the brew head. Theface of the dispenser will be flush with the face of the brew basketdrawer when in the proper position.

When using the 6 gallon dispenser with cart, the 18 gallon mobil servingtank, and the 24 gallon mobil serving tank (18 gal. and 24 gal. mobileserving tanks are not usable with the split stand), always insure thatthe coffee liners are clean and empty.

CAUTION: ALWAYS INSPECT THE COFFEE SIGHT GAUGE AND THE COFFEE LINER TOMAKE SURE IT WILL HOLD THE NUMBER OF 6 GALLON BREWS YOU INTEND TO MAKE.The carts are parked under the brew head/heads with the operatorsteering handles and faucets facing out. Make sure that the front faceof the coffee compartment is flush with the face of the brew basketdrawer. When using the 6, 18 and 24 gallon carts, make sure that thebrew basket opening is above the coffee dispenser cover opening/s.

CAUTION: ALWAYS SET BOTH PARKING BRAKES ON THE CART. The brakes shouldbe set whenever the cart is not traveling and not under “hands oncontrol” of the operator. NEVER park the cart under the brewer with out,A) insuring it is fully in the brew position, and B) setting the parkingbrakes. The brakes are set by pressing your foot on the paddle 37 asseen in FIG. 1B just above and to the rear of each steerable wheel 64E.When the brakes are set, a green button extends above this paddle. Thisgreen button is the brake release button. The brakes are released fortraveling by pressing the green button with you foot. For a moredetailed description on using the cart, refer to the appropriate cartsoperation manual.

Referring back to FIG. 5B, to start the brew cycle, press the brew startswitch 50. If the ready light 48 is on, the brew start switch light willstart flashing and the brew cycle will start immediately. If the readylight is not yet on, the brew start switch light will turn on but notflash. The brew start switch light remains on but not flashing to alertyou that the brew start has been selected and that the brew will startautomatically as soon as the ready light illuminates.

Referring now to FIGS. 4B and 5A on the twin brewer with the transferoption you have the option on each brew head to select an automatictransfer of the finished coffee to a 60 gallon stationary holding tank144 at the end of the brew cycle. First, move the transfer hose 418 asseen in FIG. 4A from the parking position on the side of the brew headyou want to transfer. Insert it into the top of the sight glass 66F onthe dispenser after removing the vent cap 420. Second, select theTransfer, Automatic, ON push button above the brew head you wish totransfer to holding tank activating pump 303 to pump the freshly brewedbeverage form the urn through conduit 132 and into the holding tank 124.The Transfer, Automatic, ON push button 128, can be selected at any timeduring the brew cycle. The brew head will now automatically transfer theentire contents of the dispenser to the holding tank at the end of thebrew cycle. After a brew cycle has stopped you can also transfer coffeewith the manual button in 2 ways. One, select the Transfer, Automatic,ON push button and momentarily press the manual transfer button 130.This will start a timed transfer just as it would do if transfer hadbeen selected during the brew cycle. the second method, place theTransfer, Automatic, ON push button in the OFF position and hold themanual transfer button 130 in until the transfer is complete.

You can stop the brew and transfer cycles on either side by pressing theappropriate stop button, or by pressing the appropriate power button tothe off position. You can also shut down both sides at the same time bypressing the emergency stop palm switch in the center of the brewer. Ifyou stop the brew head in the middle of a brew cycle, you will have tobegin a new brew cycle from the beginning. You can not restart a brewcycle after it has been stopped. If you stop the brew head in the middleof a transfer cycle you can finish the transfer by holding in theTransfer, Manual push button 130.

Pressing the Emergency stop push button 442 will remove power to thebrewer and cancel all functions on both sides. If the problem can beisolated to one side only, the power switch to the offending side can beturned off and the emergency stop switch reset. This will allow the goodside of the brewer to continue to function.

Carefully inspect and empty the brew basket as soon as rapid drippinghas stopped and you are sure that there is no longer any water trappedabove the coffee bed in the brew basket.

For overnight/short term storage of the brewer and dispensers do thefollowing. Make one full brew in each head, without coffee in the brewbasket, and the Automatic transfer in the ON position. This water onlybrew will push hot rinse water through all coffee barring tubes andcomponents to the holding tank. This will leave only clean fresh waterin the pump and lines. Remove the brew basket and wipe the area abovethe basket with a cloth to remove the coffee oils that collect there.Brew systems must not be left for long term storage until after athorough cleaning.

Each brewer uses the same parts. I.E. a twin brewer is really 2 completesingle brewers in the same cabinet. The computer allows both brew headsto operate on the same wall circuit breaker if need be. A twin brewercan easily be converted in the field with the transfer feature by addingthe transfer kit. All holes and connections are provided.

Main control board and computer. The function of the main control boardis to manage the timed functions, interface with the operators switches,remember the operator switch commands until they can carried out, systemerror detection, and the heater electrical power management in anintegrated fashion. Each brew head has its own main control board. Themain control board carries the computer and the timers. Watertemperature is controlled by the thermostat exclusively but the decisionof when and which water tank in a twin brewer is allowed to heat is madeby the main control board. Water level in the hot water tank/s is sensedby the liquid level control boards dedicated to each tank. The maincontrol board monitors the LLC to insure the brewer is ready for thenext brew cycle and inhibits the fill cycle during the brew cycle.

Fill system/liquid level control board. The function of the fill systemis to control the incoming water so as to maintain a sufficient amountof water in the brewer to complete a coffee brew cycle. Each brew headhas a separate hot water tank and each tank has its own liquid levelcontrol board (LLC). The LLC controls the hot water tank water inletvalve and provides status reports to the main control board. The LLCuses 2 water sensing probes, one upper and one lower. The water inletvalve is opened until both probes are touching water. The lower probe isused to sense the presence of enough water in the tank to allow theheaters to come on without danger of burning the heaters out. When wateris not felt by the lower probe, the LLC signals the main control boardto prevent the heaters from coming on. The upper probe senses when thehot water tank is full to the brew level. When the upper probe senseswater, it turns off the water inlet valve and signals the main controlboard to allow the next brew cycle. During the brew cycle, the waterinlet valve is inhibited by the main control board from refilling thehot water tank. When water is taken from the hot water tank during theactivation of the flush button, the LLC automatically refills the tankto the brew level again.

Heating system. The function of the heating system is to bring thetemperature of the incoming water up to the proper degree to brewcoffee. Each brew head has a separate hot water tank and each tank hasits own thermostat. The thermostat is preset at the factory to 205degrees F. The thermostat operates independently of other systems in thebrewer but can be inhibited from heating in 3 ways. 1) if there is notenough water in the hot water tank to reach the lower water level probe,as in the first start up after installation or loss of water supply,heat is inhibited by the LLC via the main control board. 2) during thebrew cycle, heat is inhibited by the main control board. 3) if the maincontrol boards on two brew heads are connected by a communicationscable, the main control board will allow only one set of heaters to drawfrom the incoming power source at a time. Which ever tank calls for heatfirst will lock out the other tank until it is done. The second tankwill begin heating as soon as the first tank finishes. The thermostatwill attempt to heat whenever the water falls below 204 degrees.

Dispense systems. The function of the dispense system is to deliver brewwater to the brew basket to accomplish the brewing of coffee. Thedispense system for each brew head is comprised of a brew valve and brewtimer, a bypass valve and bypass timer, the spray disc and bypass donut,and the hot water tank. The main control board interfaces the operatorbrew start and brew stop buttons to these valves. The flush button opensthese two valves directly and does not go through the main controlboard. The maximum water volume of 6 gallon is permanently set by thefactory by way of the position of the brew and bypass valve at the 6gallon level on the side of the hot water tank. The brew timer is set tohold the brew valve open until the 6 gallons has drained from the tank.On models with the transfer feature, the brew time is extended beyondwhat is required to finish a 6 gallon drain to delay the transfer pumpcycle. This delay time (brew time extension) is set to allow the coffeetransfer pump to begin at such a time as to allow the pump to finishshortly after dripping from the brew basket stops. These steps in thetiming cycles allow transfer brewers to be adjusted for maximum brewvolume per hour. The main control board on all brewers inhibits the LLCfrom refilling the hot water tank until the brew and bypass valvesclose. This interaction of valve position and tank filling guaranteesthat the brew volume is both repeatable and predictable. The repeatableand predictable nature of the dispense system allows the timer to be setto allow any amount of brew temperature water up to 6 gallons to drainas well. The brew valve empties onto the spray disc. The spray discseparates the brew water into a large number of separate streams toshower the entire surface of the coffee bed in the brew basket with hotwater. The bypass timer is set to hold the bypass valve open to achievethe desired percentage of bypass. The bypass valve empties the bypasswater into the bypass donut where it is diverted around the coffee bedin the brew basket and into the coffee container along with the brewedcoffee. From 0 to 40% of the brew water volume can be diverted in thismanor. The main control board can delay the start of the brew cycleuntil the brewer is ready. I.E. proper temperature, full water tank, andthe transfer if applicable is complete.

Transfer systems. The transfer system consists of the transfer pump,transfer timer, and transfer pickup hose with sight glass adapter. Eachbrew head has a separate transfer system. The transfer system isactivated in three different ways. One, when the automatic transferswitch is in the ON position, the main control board will cause thetransfer pump to run automatically for the amount of time set on thetransfer timer at the end of each brew cycle. Two, the timed transfercycle can be started at any time by placing the automatic transferswitch in the ON position and momentarily pushing the manual transferbutton. The third way to start the transfer pump is to push theautomatic transfer switch to the OFF position and hold the manualtransfer button for as long as required to complete a stopped transferor to clear preheating water from the container. The transfer cycle doesnot delay the hot water tank from heating or filling but will delay thestart of the next brew cycle until the transfer pump is off.

The power SWITCH 46 (ON/OFF), extended push button, latching switch. Thepower on/off switch light is on with the switch in the on position. Theswitch turns the power on/off only to the brew head below the switch.

The ready light 48′ is on when the hot water tank connected to the brewhead below the light is full of water, and water is up to the propertemperature, and when the transfer, if selected, has finished. Thetransfer function does not delay the fill or heating functions. Eachbrew head on the brewer has a ready light. How long it takes for theready light to come on the first time each day and between brews dependson the electrical specifications issued when the brewer was ordered.Depending on the electrical power available, twin brewer may beconfigured to allow only one brew head to heat up at a time. This delayin the heating process is important only during a cold start when thefirst brew head must come up to temperature before the other head canstart to heat. After a cold start heat delay, the normal heat delaydrops to only a few minutes. Depending on the electrical power and watertemperature available, the normal heat delay may not be noticed by theoperator.

The brew start switch 50, momentary push button, with light 50′. Tospeed the brew cycle, the Brew/Start can be selected before the brewhead is ready. If the Brew/Start is selected before the brew head isready, the Brew/Start light will turn on and remain on while waiting forthe brew head to become ready. Three conditions must be met before thebrew head will become ready and start the brew cycle. The tank must befull of water, and the water must be up to temperature and the automatictransfer if selected must finish its cycle. If the Brew/Start switch hasalready been pushed, the brew head will automatically start the brewcycle when these three conditions have been satisfied. The Brew/Startlight will flash during the actual brew cycle.

The stop switch 52, momentary push button, no light. This switch stopsand cancels the brew and or transfer cycles of the brew head below theswitch. The brew transfer cycle can not be restarted from the point thatthey were stopped. If the brew cycle is canceled, you must start over.If the transfer cycle is canceled you can finish the transfer with themanual transfer push button.

The transfer switch 128 (ON/OFF), latching push button, with light. Thelight is on, but not flashing, when the automatic mode has been selectedfor the brew head below the switch and then flashes during the automatictransfer cycle or while the manual transfer button is held down. Thetransfer cycle will begin automatically when the brew cycle has finishedand drip out from the brew basket is nearly complete. Drip out should becompleted before transfer has finished. A complete transfer can bestarted at any time by placing this switch on the ON position andmomentarily pressing the manual transfer button.

The transfer manual switch 130 (HOLD),momentarily push button, no light.The transfer pump connected to the brew head under the button will runfor as long as this button is pressed. The automatic transfer on/offswitch will flash while the transfer pump is running. A completetransfer can be started at any time by placing the automatic transferswitch in the ON position and momentarily pressing the manual transferbutton. The manual transfer button can be used to move coffee into theholding tank at any time. This button can also be used after flushingthe brew head into the dispenser to rinse the transfer pump and lines toholding tank.

The flush switch 54 (HOLD), momentary push button, no light. Press andhold the flush button to open both the brew and bypass valves in thebrew head under the button. Hot, brew temperature, water will flow intoand through the brew basket and bypass donut into the dispenser for aslong as this switch is pressed. This function is used primarily to rinsethe brew head at the end of the operating cycle, shift, or day. Flushcan also be used to preheat the brew head and dispensers before theirfirst use of the day.

CAUTION: You can overfill the Dispenser if you hold this button in longenough.

NOTE: After flushing each brew head into dispensers, we suggest you usethe manual transfer buttons to rise the transfer pumps and lines toholding tank. After the manual transfers are completed, open the rinsejet in each holding tank and finally drain the holding tank/tanks.

The emergency stop switch 442 (PULL TO RESET) latching palm size pushbutton, with light. Push the emergency stop button to disconnect allelectrical circuits and cancel all functions in the brewer. Pull theemergency stop button to reset the brewer. The emergency stop buttonlight is on when the button is pushed in to the stop position. Theemergency stop button should not be reset until after, A) the fault hasbeen isolated to the offending side and the appropriate power switch hasbeen turned off. This will allow the good side of the brewer to still beused before repairs are accomplished, or B) the emergency situation hasbeen identified and resolved.

10 AMP CIRCUIT BREAKER (PUSH TO RESET), protection is provided to eachbrew heads electrical components and function switches by separate 10amp. breakers.

2 AMP CIRCUIT BREAKER (PUSH TO RESET) This breaker is connected justbefore each heads transfer pump and will isolate the pump from the restof the brew head. Should the pump fail, the brew head can still be usedto brew directly into a dispenser or cart.

Tank temperature is set at the factory at 7 degrees F below boiling or205 degrees F at sea level. This adjustment must be reduced at altitudeby the same 7 degrees from the boiling point of water at your altitude.Actual brew water temperature will be reduced by the heat transfer ofthe dispense components to the desirable temperature of 195 degrees F.

Brew Timer. (front timer) Adjustable in one second increments The timerequired on this adjustment will need to be the minimum time required toclear the hot water tank of the complete 6 gallons needed for brewing.Brewers with the transfer option will require additional time (variableto each coffee, grind, weight, and spray disc selected) needed for dripout. The object of this additional time is to delay the transfer starttime long enough to insure the transfer finish time is only slightlylonger than the time needed for the brew basket to finish rapiddripping. The proper amount of time added to the minimum brew timeinsures that the transfer will be complete and that the dispenser willbe empty for the next brew. If the additional time is longer thanneeded, the gallons per hour of coffee production will be reducedunnecessarily. Always inspect the dispenser to verify that a transferwas successful before starting another brew cycle. Remember that thetransfer time is also adjustable and will effect this adjustmentslightly.

Bypass Timer. (middle timer) Adjustable in one second increments

Refer to the bypass chart below for settings needed to obtain any % ofbypass required. Remember, both the bypass timer and the brew timer mustbe adjusted when changing the bypass percentage. Essentially this meansthat as you increase bypass % the brew time will need to be reduced andvisa versa. Please refer to the chart because these changes are notequal I.E. 25 seconds up on the bypass timer does not mean 25 secondsdown on the brew timer.

Timer settings - With/out TRANSFER Extend minimum brew time to suittransfer % of Bypass Timer Minimum Brew Time Bypass Seconds = Vol.Seconds = Vol.  5%  .3 5.7 Gal. Gal. 10%  .6 5.4 Gal. Gal. 15%  .9 5.1Gal. Gal. 20% 1.2 4.8 Gal. Gal. 25% 1.5 4.5 Gal. Gal. 30% 1.8 4.2 Gal.Gal. 35% 2.1 3.9 Gal. Gal. 40% 2.4 3.6 Gal. Gal.

Transfer Timer. (back timer) Adjustable in one second increments

Transferring coffee from the dispensers is a very fast process. Transfercan be automatically started at the end of the brew cycle or manuallytransferred at any time by holding the manual switch down. The brewtimer setting will determine the start of the transfer timed cycle. Thetransfer timed cycle could be considered a fixed time. However, the brewtimer must be set so that the transfer timer will stop shortly after thebrew basket has stopped rapid dripping. Remember that the brew timerdoes not control the brew water volume. Brew water volume is factory setby the dispense fitting location in the hot water tank. The brew timerdetermines how long the brew dispense valve remains open after the brewwater volume has passed. The time on the brew timer is extended past thetime required for brew water delivery to delay the start of the transfertimer. The chart below illustrates this overlap.

START Total brew time FINISH MINIMUM Brew water delivery Brew Baskettime required drip out BREW TIMER SETTING TRANSFER TIMER

The average time on the transfer timer will be between ??? Sec and ???sec. The actual transfer time will very slightly due to the length ofthe delivery hose used to connect to the holding tanks. The transfertimer should be adjusted to the minimum time needed to complete thetransfer. The brewer computer will prevent another brew until thetransfer is completed.

Proceed as follows to adjust a brewer with the transfer option.

Transfer auto on/off switch in the off position. Complete a brew, withcoffee, into a 6 gallon dispenser and record the total time requiredincluding drip out of the brew basket. You will need to judge foryourself what level of dripping from the basket is acceptable whenstopping the total time.

Manually transfer the finished brew from the dispenser to the holdingtank. The timing should be stopped when air clears the lines connectingthe brewer to the tank. Record the total transfer time.

Subtract the total transfer time from the total brew time to get thetotal seconds needed to be entered on the BREW timer.

Brew water to coffee contact time.

Coffee contact time can be controlled by the size and total number ofholes placed it the spay disc on the spray assembly and spray assemblyperformance chart should be consulted for the desired amount of contecttime.

Select your coffee grind below-then the contact Coffee time at left Con-Coarse Med. Grind Fine Grind Custom Grind tact Grind hole hole hole holeTime-Min. # Size Pattern # Size Pattern # Size Pattern # Size Pattern4.0 Min. 4.5 Min. 5.0 Min. 5.5 Min. 6.0 Min. 6.5 Min.

Leveling.

It is very important that the brewers, counters and stands be leveledwith an accurate spirit level. Each brewer, counter, and stands haveadjustable feet. Leveling must be done prior to bolting the feet down.If the foot mounting holes for bolting are not aligned with the holesprovided when the brewer is level, a slightly back lean is preferred toany forward leaning of the brewer. (define maximum travel from full into a full out. I.E. number of turns.)

3 kinds of actuators, 1 kind of lamp holder, 1 kind of coupling, 1 kindof cover

Ready, Start, and transfer lamps will flash at the same time when thereis a computer error.

Each light has a 1 W 1100 ohm resister attached ahead of the light. Thisreduces voltage to the light to 90 volts. This voltage reduction extendslight life by 5 X.

POWER switch 46 (ON/OFF) single contact N.O., extended button, latching,Lamp 46′ on with switch in the on position. Turns power on/off only tothe brew head below switch READY lamp 48′ (TO BREW) lamp only, lamp onwhen tank is full of water, and when water is up to temperature.Indicates ready to brew for brew head below lamp.

BREW switch 50 (START) single contact N.O., momentary button. Start/brewcan be selected before the brewer is ready. Start/brew Lamp 50′ willremain on while waiting for brew to start (when temp., water, ortransfer are not yet ready). When the tank is full of water, propertemperature has been reached, and the transfer has completed ifapplicable, the brew will start automatically. The lamp will flashduring the actual brew cycle.

STOP switch (BREW or BREW/TRANSFER) single contact N.C., momentarybutton, no lamp. Interrupts and or Resets brew and transfer functionspreviously selected.

TRANSFER-AUTOMATIC switch 128 (ON/OFF) single contact N.O., latching,Lamp 128′ on when auto mode is selected and flashes during transfercycle. Used on brewers with transfer only. Transfer will beginautomatically when the brew has finished and drip out is nearlycomplete. Drip out should be completed before transfer has finished. Acomplete transfer can be started at any time by placing this switch inthe ON position and momentarily pressing the manual transfer button.

TRANSFER-MANUAL switch 130 (HOLD) single contact, N.O., momentarybutton, no lamp. Used on brewers with transfer only. Transfer pump willrun for as long as this switch is pressed. The automatic transfer on/offswitch will flash while the transfer pump is running. A completetransfer can be started at any time by placing the automatic transferswitch in the ON position and momentarily pressing the manual transferbutton. Can be used to move coffee into the holding tank at any time orafter flushing the brew head to rinse the transfer pump and lines toholding tank.

FLUSH switch 54 (HOLD) 2 contacts, N.O. momentary, no lamp, press andhold to energize both brew and bypass valves. Hot brew water will flowinto the brew basket and bypass donut for as long as this switch ispressed.

EMERGENCY STOP switch 442 (PULL TO RESET) 2 ea. contacts N.O./N.C. pushto open circuit and pull to reset, lamp is on when the button is pushedin to the stop position. Used on brewers with transfer only. The E stopterminates all functions in the brewer. Only the hot side of the mercuryrelay and the wire to the E stop switch will have voltage when in thestop position. The E stop should not be reset until after, A) the faulthas been isolated to the offending side and the appropriate power switchhas been turned off. This will allow the good side of the brewer tostill be used before repairs are accomplished, or B) the emergencysituation has been identified and resolved.

10 AMP CIRCUIT BREAKER (PUSH TO RESET) Control board power comes fromthe incoming electrical terminal block, through the E stop switch on ATmodels, to the 10 amp breaker, then to the power switch for theappropriate head in the brewer. Each brew head has its own 10 ampbreaker. For A models (no transfer) it goes from the terminal block, tothe breaker, to the power switch.

2 AMP CIRCUIT BREAKER (PUSH TO RESET) This breaker is connected justbefore the transfer pump and will isolate the pump from the rest of thebrewer. Should the pump fail the brewer can still be used to brewdirectly into a dispenser or cart.

Main control board and computer. EPROM software 3 identical timers thatare interchangeable between any position,

Front=brew valve timer, set in seconds to insure a complete 6 gallondrain through the dump valve. This timer is extended on AT models todelay the start of the transfer pump.

Middle=bypass valve timer, set in seconds to obtain from 0 to 40% ofbypass. A change in the bypass timer will require a change in theopposite direction on the brew timer. refer to

Back=transfer pump timer, set in seconds to insure a completely emptydispenser and lines. This time will vary in accordance to the length ofthe transfer hoses.

All incoming and outgoing signals easily traced to connectors.

The stand alone jumper can be used for service but only one jumper at atime to prevent both heaters to draw incoming power at a time.

Same board can be used in all models left or right. However, you can'tinterchange domestic and export voltage boards or components.

Communication cable has three wires, transmit, receive, and ground. Theend of the cord with a loop designates that board as the slave. If thecommunication link is broken the slave is disabled. If the incomingpower circuit breaker is large enough to supply both hot water tanks astand alone jumper is plugged into each of the main control boards toallow them to act independently of each other. If an error is detectedduring a brew, the brew is allowed to finish but that brew head isdisabled. Errors can be reset by powering down the brewer ( both headson a twin brewer ) and powering it back up again.

Fill system/liquid level control board.

Controlled by a dual probe liquid level board. std. to our HWBs.

Tank does not refill during the brew cycle.

This allows the dispense valve to precisely control the amount of watercoming through because the standing water pressure is known for allwater quantities from 0 to 6 gallons.

Tank does refill automatically during and after flushing.

Fill valve is std. S-45. one for each side ,as necessary, tied to a ⅜ Tfitting.

Unaffected by water pressure or flow rate.

Brewer will not brew until the tank has sufficient water regardless howlong it takes to fill and therefore all brews will be exactly 6 gallons.The dump valve is located at a point exactly 6 gallons below the fulltank level. The brew timer is set to insure that the dump valve is openlong enough to allow all 6 gallons to drain out. The valve time isextended beyond what is required to finish a 6 gallon drain, on ATmodels, to delay the transfer pump. This delay time set to allow thecoffee transfer pump to begin at the right time to allow the pump tofinish shortly after drip out from the brew basket. These steps in thetiming cycles allow the brewer to be adjusted for maximum brew volumeper hour.

Refilling the hot water tank is prevented until the brew dump valve hasclosed, indicating the end of the brew cycle. See the dispense systemfor filling the dispensers.

Heating system.

Hot water tanks on all brewers, left or right side are identical 18gallon tanks.

Standard thermostat and probe can be used. Production thermostat mayhave connectors mounted on the other side for ease of assembly.

Heaters are 10 kw 240 V, 5 kw 240 V, 10 kw 480

Mercury relays are 80 amp 3 ph, 60 amp 3 ph,

Both hot water tanks and heaters in the twim brewer 30 and twin brewer30 with transfer option are connected to one breaker. The computercontrols the relays and allows only one tank to heat at a time. I.E. 2tanks drawing 31 amps each can be connected to one 50 amp breaker, orboth can heat at the same time if connected to a 80 amp breaker. Heaterconfigurations can be installed to maximize incoming power.

Dispense systems.

The sprayhead disperses the brew water from the brew dump valve over thecoffee bed by 37 evenly spaced holes like a hot rain shower.

Transfer system.

Transfer is accomplished by a ¼ hp self priming pump.

Each pump is connected to a 2 amp circuit breaker.

While a detailed description of the brewing systems and method has beendescribed with reference to the brewing of coffee, it should beappreciated that coffee is merely an example of a number of differenttypes of ingredients that can be employed with the brewers of theinvention to create a brew, such as tea and cocoa. In addition, althoughthe best mode of practicing the invention has been described, it shallbe appreciated that the invention is not merely limited to such details.

What is claimed is:
 1. In a brewing system having a hot water dispensertank for containment of a preselected amount of water needed for acomplete brew cycle, means for selectively dispensing the hot water inthe hot water dispenser tank into a brew basket during a brew cycle anda manually actuatable brew cycle start switch for initiating the brewcycle, the improvement being a brew cycle controller, comprising: meansfor sensing when the hot water dispenser contains the preselectedquantity of water needed for a brew cycle; and means for storing theoccurrence of manual actuation of the brew cycle start switch; and meansresponsive to both the storing means and the sensing means forcontrolling the selective dispensing means to delay dispensing of waterinto the brew basket in response to an actuation of the brew cycleinitiation switch until the sensing means senses that the preselectedquantity of water needed for a brew cycle is contained in the hot waterdispenser tank if the brew cycle start switch is actuated to start abrew cycle before the hot water dispenser tank contains the preselectedamount of water.
 2. The brewing system of claim 1 including means forsensing whether the temperature of the water in the hot water dispensertank has at least reached a preselected minimum temperature, and inwhich the dispensing controlling means is responsive to the temperaturesensing means to delay dispensing of water in response to an actuationof the brew cycle start switch until both the temperature sensing meanssenses that the temperature of the hot water in the hot water dispensertank has reached the preselected minimum temperature in addition todelaying the start of the brew cycle in response to the quantity sensorsensing that the preselected quantity of water need for a brew cycle iscontained in the hot water dispenser tank if the brew cycle start switchis actuated to start a brew cycle.
 3. The brewing system of claim 1including an indicator light associated with the brew cycle start switchand having two different first and second modes of operation, and meansresponsive to the dispensing controlling means for controlling the modeof operation of the indicator light in accordance with whether thedispensing of water into the brew basket in response to actuation of thebrew cycle start switch is being delayed.